Fabrication and mechanical testing of porous calcium phosphate bioceramic granules

Porous hydroxyapatite/tricalcium phosphate (HA/TCP) granules were fabricated by a novel technique of vacuum impregnation of reticulated polyurethane (PU) foams with ceramic slip. The resultant granules had 5-10% interconnected porosity with controlled pore sizes necessary to allow bone ingrowth combined with good mechanical properties. Using PU foams with a different number of pores per inch (ppi), porous HA/TCP granules in the size range of 2-8 mm were successfully manufactured. Dieplunger tests were used to compare the compression and relaxation properties of the granules with those of a commercially available bone graft product, BoneSave. The results of the die-plunger testing showed that the experimental granules were stiffer than the BoneSave materials and had less of a tendency to crumble to powder after testing. This therefore suggests that these experimental granules would be useful for impaction grafting and space filling applications.